Suzuki Eiger 400 LT-A400/400F ATV Service Manual, 2002–2007 (P/N 99500-43045-01E)

This Suzuki factory service manual covers the 2002–2007 Eiger 400 LT-A400 and LT-A400F ATVs (P/N 99500-43045-01E). The main repair chapters cover the K2 models, and the K3 through K7 supplements document model-year changes for the 2WD LT-A400 and the LT-A400F with selectable 2WD/4WD.

PDF Navigation and Wiring Diagram Detail

Text search and bookmarks are available for the main service text. Bookmarks jump to the main chapters, model-year supplements, and wiring diagrams. Use zoom to read the small component labels and wire-color codes on the diagrams. Search for the diagram headings in the contents or use their bookmarks to reach the sheets.

The download is one printable English PDF with 424 pages. The main manual occupies 354 pages, including the original cover, and the five supplements occupy 70 pages. The total includes nine blank or header-only pages, two within the supplements.

Engine Overhaul, Drivetrain Service, and Electrical Testing

This selection of workshop topics also points to less obvious coverage, such as the fuel-level gauge and recoil starter.

• Scheduled maintenance covers service intervals, air cleaner service, valve clearance, oil and filter changes, gear oil, clutch lock-up inspection, and drive belt replacement.
• Engine and automatic drivetrain procedures cover engine removal, cylinder head and valve work, piston and crankshaft inspection, oil pump service, and overhaul of the wet-shoe centrifugal clutch, V-belt pulleys, and hand-operated range transfer.
• Differential and final drive sections cover bearing and seal inspection, shim selection, backlash, and tooth-contact checks. Front differential and 2WD/4WD shift mechanism procedures apply to the LT-A400F.
• Chassis and brakes coverage includes LT-A400F front drive shafts, wheel hubs, front disc brakes, master cylinder and calipers, rear drum brake, brake bleeding, steering and toe-in, suspension, swingarm, and rear axle service.
• Fuel, cooling, and electrical systems coverage includes Keihin carburetor overhaul, fuel-valve service, SACS oil cooling and lubrication, cooling fan and switch tests, and charging, starting, ignition, lighting, and battery diagnosis.
• Workshop reference data includes exploded assembly views, troubleshooting tables, wiring and routing diagrams, special-tool numbers, tightening torques, capacities, and wear limits.

Suzuki wrote the manual for mechanics who already have the service knowledge, workshop equipment, and special tools the procedures call for.

How the K3–K7 Supplements Build on the K2 Manual

Use each supplement alongside the applicable earlier chapters. K3-I adds specifications and front-end reassembly information. K3-II adds transfer and gearshift-cam work, rear-end reassembly information, regional wiring diagrams, and cable routing. The K4 chapter adds universal-joint and front propeller-shaft flange-coupling information plus revised wiring and routing. K5 and K6 update torque and service data, including K5 front caliper mounting-bolt treatment. The K7 chapter covers revised front brake hose routing and carries forward K6 specifications and service data.

Repair Decisions and Shop References

Engine access and electrical fault isolation. The engine chapter identifies which components can be serviced in the frame, so you can check whether a job calls for engine removal before planning the teardown. The electrical chapter pairs charging fault charts with generator output and regulator/rectifier tests, and includes starter motor overhaul and ignition coil testing.

Diagrams and tools. The cylinder-head cooling and engine lubrication charts trace the oil circuits. K2–K4 wiring diagrams and harness, carburetor hose, and brake hose routing views help identify connections and routing. The tool index lists the crankshaft installer 09910-32812, crankcase separator 09920-13120, driven-face spring compressor 09922-31430, drive shaft remover 09924-21930, multimeter set 09900-25008, and oil pressure gauge 09915-74511.

Repair cautions. The manual warns that using the wrong crankshaft installation method can affect alignment and that compressed air can damage the carburetor diaphragm if it is still installed. Engine removal, driven-face spring work, brake service, and fuel-system repair require the specified workshop equipment and the manual's safety procedures before work begins.

Valve Clearance and Oil Capacity Preview

For both K2 models, the maintenance chapter specifies cold valve clearance of 0.05–0.10 mm at the intake and 0.22–0.27 mm at the exhaust, measured at top dead center on the compression stroke.

The K2 oil service data lists 2.9 L for an oil-only change, 3.1 L with filter replacement, and 3.4 L after engine overhaul.